Backed carpet and method of producing the same



Oc`t. 23, 1962 D. B. PARLIN Erm.

BACKED CARPET AND METHOD OF PRODUCING THE SAME 2 Sheets-Sheet 1 FiledNov. 16, 1959 x :3.: :ggg QWKVWKM,

INVENTORS DAVID Bw PQELIN WILLJHM J. ELLIOTT ATTORNEYS Oct. 23, 1962 D.B. PARLIN ETAL BACKED CARPET AND METHOD OF PRODUCING THE SAME 2Sheets-Sheet 2 Filed NOV. 16, 1959 INVENToRS DAVID B. PQEL/IN gflLLmM JELLIOTT wedWv/ Qrvjo @News United States Patent 3,060,072 BACKED CARPETAND METHOD F PRDUCWG TIE SAME David B. Parlin, Thompsonvilie, Conn., andWilliam Ii.

Elliott, Longmeadow, Mass., assignors to Bigelow-Sanford, Inc., acorporation of Delaware Filed Nov. 16, 1959, Ser. No. 853,368 Claims.(Q1. 156-72) The present invention relates to backed carpet and themethod of producing the same. `lt relates, more particularly, to abacking which is especially useful in conjunction with tufted carpet andthe -method of forming such backing on a carpet.

An object of the present invention is to provide a backed carpet whichis dimensionally stable and which has substantial bulk or body. Carpetembodying the present invention is substantially immune to shrinkage andthus, can be washed or shampooed without fear of dimensional changes.Another object of the invention is to provide an economical method offorming such a backed carpet.

A further object of the present invention is to provide a method ofapplying a layer of reinforcing material and the binding of the pileelements to the base of the carpet without materially increasing thecost of the carpet while at the same time producing a carpet of superiorquality.

Although the present invention is not necessarily limited to tuftedcarpet, it is particularly advantageous in conjunction with tuftedcarpet. Generally speaking, tufted carpet lacks bulk or body anddimensional stability because the pile elements are ordinarily formed ona relatively imsy base, such as burlap or lightweight canvas and thepresent invention corrects these deficiencies to a large extent. In thisconnection, it should be noted that it has been customary to apply abackcoating of an adhesive material such as a latex compound to carpet,especially tufted carpet, to bind the pile elements in place and toprotect the back of the carpet. However, it has also been foundnecessary in many instances to apply reinforcing materials of variouskinds and thicknesses to the back of the carpet in order to obtain thedesired dimensional stability. This of course, adds materially to thecost of the carpet and due to the nature of the reinforcing material hasnot been entirely satisfactory.

In accordance with the present invention, increased bulk and dimensionalstability in the carpet are obtained by attaching a layer of fibrousmaterial to the base of the carpet in such a way that fibers from thelayer not only extend into the material forming the base of the carpetbut in some instances penetrate the yarns forming the pile elements. Anadhesive material in liquid form is then applied to the layer of fibrousmaterial, and the layer of fibrous material with the adhesive thereon isthen compacted into a relatively thin layer impregnated with theadhesive material. The adhesive material binds the fibers forming thelayer of fibrous material together while at the same time bonding thelayer to the base of the carpet and securing the pile elements in place.

Other objects and advantages of the present invention will be apparentand better understood from the following description and theaccompanying drawing in which:

FIG. l is a side view in vertical section diagrammatically illustratinga tufted carpet on an enlarged scale;

FIG. 2 is a side view in vertical section diagrammatically illustratingthe carpet shown in FIG. l with a layer of fibrous material attachedthereto;

FIG. 3 is a side view in vertical section diagrammatically illustratingthe carpet of FIG. 2 after final treatment in accordance with andembodying the present invention;

FlG. 4 is a diagram-matic view illustrating the manner attenta PatentedGet. 23 1962 ice `ly illustrating a base for a tufted carpet with alayer of fibrous reinforcing material attached thereto;

FIG. 7 is a side view in vertical section diagrammatically illustratingthe structure shown in FIG. 6 with tufted carpet loops formed thereon;and

FIG. 8 is a side view in vertical section diagrammaticalp 1yillustrating the carpet in FIG. 7 after treatment in accordance with thepresent invention.

With reference to the drawings, it will be noted that illustrations areschematic because of the nature of the structures involved. However, thefollowing description when read in conjunction with such illustrationswill provide a full and complete understanding of the invention.

As shown in FlG. l of the drawings, there is a tufted pile fabric 1dcomprising pile elements 11 in the form of loops which are supported ona base 12 of loosely woven material, such as burlap or a lightweightcanvas.

The looped pile elements 11 are formed on the base 12 in the usualmanner by a tufting machine with the thread or yarn forming the pileelements extending through the base and beyond the upper face thereof.As shown in FIG. 2, a layer 13 of loosely compacted fibrous materialsuch as jute, nylon, fiber glass or the like, is next attached to theunderside of the base of the pile fabric.

The layer 13 of fibrous material is attached to the base of the pilefabric by a needling operation which may be carried out on a needlingmachine, as indicated in FIG. 4. In such an operation, the fabric is fedforward in inverted position (with the pile facing down) beneath aseries of `vertically reciprocating barbed needles 15 with the layer 13of fibrous material in the form of a web on top of the base of thefabric. The layer of fibrous material is fed onto the pile fabricbeneath a guide plate 16 by a rotating feed wheel 17. As the fabric withthe layer of fibrous material advances to a point beneath the needles,they are supported on a base plate 18 and they pass beneath a needleplate 19 which contains openings '2G through which the needles pass inmovement through the layer of fibrous material and the base of thefabric. The construction of the needling machine and its operation isconventional and need not be described in detail.

The needling of the fibrous layer to the pile fabric is done in a randommanner and the needles employed should be smaller in diameter than thestrands from which the base of the fabric is formed so that such strandswill not be severed and the fabric weakened thereby. The verticalmovement of the needles with respect to the fabric will carry some ofthe fibers from the layer of fibrous material through the base of thefabric, as indicated at 13a, but this movement should be limited so thatsuch fibers will not extend substantially beyond the face of the fabricfrom which the pile elements extend. In addition, the needles will, insome instances, strike the yarns forming the pile elements, with theresult that small punctures or openings are made therein into whichfibers from the layer of fibrous material are forced, as indicated at13b. The penetration of the pile yarns by the fibers in this manner addsto the bulk or body of these elements in the carpet.

The fabric with the layer of fibrous material attached thereto is thentreated in accordance with the procedure illustrated in FIG. 5. As showntherein, the fabric with the layer of fibrous material attached theretois fed from a roll 21 with the pile facing upwardly over a steamingdevice 22 which directs steam against a layer of fibrous material on thebottom of the fabric to condition it for reception of an adhesivematerial. The layer of fibrous material is then impregnated with anadhesive material by passing it over a roll 23 4of an adhesive applyingdevice. The -roll 23 with which the layer of fibrous material contacts,is rotatably mounted in a tank 24 and is partially immersed in a supplyof suitable adhesive material 25 in liquid form which is capable ofpenetrating the layer of fibrous material.

The adhesive material used may be a Water-based emulsion of avulcanizable latex compound containing suitable fillers, pigmentingagents, vulcanizing accelerators, dispersants, antioxidants and the likeof the type which are commonly used. The adhesive material should befluid enough so that it will penetrate the layer of fibrous materialreadily and it should be of a flexible and rubbery character when cured.

An example of a suitable composition for such an adhesive 1s as follows:

Wet, Dry, lbs. lbs.

Vulcanizable Type 2000 SBR Latex 42% solids (a medlum solids latexcontaining copolymer of butaldiene and styrene) 760 319 Piccopale A20(an anionic petroleum hydrocarbon resin emulsion produced by thepolymerization of unsaturates occurring in coal tar, light oil and somepetroleum distillate fractions and consisting essentially oan indenepolymer) used as a modifier to help achieve the desired hand and alsoserving as an extender for the latex 340 170 Georgia Marble #l (Calciumcarbonate type inorgame filler to add stiffness) 500 600 Titaniumdioxide-Whitening agent 20() 200 Tamol 731 (40% sodium salt of acarboxylated polyelectrclyte) serving as a dispersng agent for thepigment and the filler 12 3 Sodium silicate (40%) used as pH stabilizerto keep the latex alkalinity high during the filler addition 12 5 Water86() The formulation of the 319 parts of Type 2000 SBR latex referred toabove is as follows:

Dry parts 2000 SBR 100.00 KOH, pH stabilizer to keep latex alkaline 0.25

Wingstay S (alkyl aryl phenol) inhibits degradation and discoloration ofthe compounded latex The adhesive applying roll 23 preferably rotates ina direction opposite to the movement of the fabric and the layer ofbrous material. A doctor blade 26 which contacts the bottom of thecarpet after application of the adhesive material spreads the coating ofadhesive material over the bottom of the carpet uniformly and returnsthe excess to .the supply tank. Sufficient adhesive material is appliedto the back of the carpet to impregnato the layer of fibrous materialand to penetrate into the base of the pile fabric and -any smallpunctures or openings therein.

After the adhesive material has been applied, the layer of fibrousmaterial is then subjected to the action of a burnishing roll 27 whichrotates in the same direction as the fabric and the layer of brousmaterial is moving, but at a greater speed. The burnishing wheelcompacts the impregnated layer of fibrous material to a thin layer 30 ofsubstantially uniform thickness having a relatively smooth bottomsurface and it also aids in forcing the adhesive material through thelayer of fibrous material into contact with the base of the pile fabricand into small openings or interstices therein. Thereafter, the adhesivematerial is dried and cured by passing `fhe fabric with the compactedlayer of impregnated fibrous material through a suitable drying andcuring oven 28. After leaving the drying and curing oven, the finishedcarpet may then be wound into a roll 29. Rolls 3S apply tension to thecarpet as it passes over the adhesive applying roll and the burnishingroll.

In :the finished carpet, the pile elements are securely bound in placein the base by the adhesive material and the compacted layer 30 offibrous material is firmly attached to the base by the fibers whichextend into the base and the bonding action of the adhesive material. Inaddition, the adhesive material bonds the fibers of the compacted layertogether and imparts substantial strength to it. As a result, the layerof fibrous material resists dimensional changes in the fabric due tostretching, shrinkage or the like.

The web or layer of fibrous material, as initially applied, may have athickness of approximately one-eighth of an inch or slightly more. Afterthe adhesive material has been applied and the layer has been subjectedto the action -of the burnishing wheel, its thickness will have beenreduced to one-sixteenth of an inch or less and the individual fiberswill be securely bonded together by the adhesive material. This impartsconsiderable tensile strength to the layer which will resist anytendency of the fabric to stretch or shrink. After burnishing, the lowersurface of the layer is relatively smooth and lint free.

The compacted layer of fibrous material not only adds dimensionalstability to the carpet and increases its body or bulk, but it alsoprovides a tough flexible covering which protects the base of the fabricand the pile elements formed thereon.

As shown in FiGS. 6, 7, and 8, the construction of the carpet may bemodified by first attaching a layer 31 of fibrous material to a base 32of burlap or the like, by a needling operation and then forming pileelements 33 thereon by a tufting operation. The pile fabric with thelayer of fibrous material attached thereto are then subject to theoperations described above in conjunction with FIG. 5 so that the layerof fibrous material is impregnated with an adhesive material and isreduced in thickness to form a compacted layer 34.

It will be understood that various other modifications may be made inthe embodiments of the invention illustrated and described hereinwithout departing from the spirit or scope of the invention as definedby the following claims.

We claim:

l. Pile carpeting having improved dimensional stability which comprisesa base element, a plurality of pile elements supported by and extendingfrom one face of said base Yelement and a dirnensionally stablecompacted layer of fibrous material extending over and being permanentlysecured to an opposite face of the base element, said compacted layerbeing comprised of fibers distributed at random with fibers therefromextending into engagement with the base element and a flexible adhesiveextending throughout said layer and bonding the fibers of the layeragainst movement relative to each other in a compacted condition`whereby said layer is rendered dimensionally stable, said adhesive alsobonding the layer to the base element of the carpeting and bonding thepile elements to the base element of the carpeting.

2. Pile carpeting having improved dimensional stability which includes abase element comprising a loosely woven material, tufted pile elementsformed on said base element, said pile elements having portionsextending from one face of the base element and avcompacted layer offibrous material extending over and being bonded to an opposite face ofthe base element, said layer being needled to the base element and beingcomprised of fibers distributed at random with bers therefrom extendinginto interstices of the woven material forming the base element and aexible adhesive extending throughout said layer and bonding the fibersof the layer against movement relative to each other in a compactedcondition, said adhesive also extending into the interstices in thewoven material forming the base element and bonding the compacted layerand the pile elements to the base element.

3. Pile carpeting having improved dimensional stability as defined inclaim 2 wherein the adhesive penetrates portions of the pile elementsthrough needle punctures therein and lends body thereto.

4. A method of forming pile carpeting having improved dimensionalstability which comprises the steps of forming a layer of brous materialon a rear face of a piece of pile carpeting having a base and pileelements extending from a front face of the base, applying an adhesivein a flowable state to the layer of brous material, compressing thelayer of fibrous material while the adhesive is in a owable state into acompacted condition and simultaneously forcing the adhesive throughoutthe layer and into the base of the pile carpeting, and then drying theadhesive whereby the bers of the layer are bonded together in acompacted condition and the layer is bonded to the base of the pilecarpeting.

5. A method of forming pile carpeting as defined in claim 4 wherein thelayer of fibrous material is formed on the rear face of the carpeting bya needling operation, said needling forming punctures in the pileelements and the adhesive material is forced into the pile elementsthrough said punctures in compressing the layer to a cornpactedcondition.

References Cited in the le of this patent UNITED STATES PATENTS1,825,827 Smith Oct. 6, 1931 2,303,203 Faris et al Nov. 24, 19422,349,236 Bodle May 23, 1944 2,675,337 Walker et al Apr. 13, 19542,913,803 Dodds Nov. 24, 1959 UNITED STATES PATENT OFFICE CERTIFICATE OFCORRECTION Patent No. 3,060,072 October 23, 1962 David Bo Parlin et al.l

It is hereby certified that error appears in the above numbered patentrequiring correction and theft the said Letters Patent should read ascorrected below.

Column 3, in the example, first column, line 2 thereof,

before "copolymer" insert a same example, under the heading Dry, 1bs",last line, for the total "1,19" read M197 Signed and sealed this 2nd dayof April 1963.,

(SEAL) Attest:

ESTON G. JOHNSON DAVID L, LADD Commissioner of Patents Attesting Officer

1. PILE CARPETING HAVING IMPROVED DIMENSIONAL STABILITY WHICH COMPRISESA BASE ELEMENT, A PLURALITY OF PILE ELEMENTS SUPPORTED BY AND EXTENDINGFROM ONE FACE OF SAID BASE ELEMENT AND A DIMENSIONALLY STABLE COMPACTEDLAYER OF FIBROUS MATERIAL EXTENDING OVER AND BEING PERMANENTLY SECUREDTO AN OPPOSITE FACE OF THE BASE ELEMENT, SAID COMPACTED LAYER BEINGCOMPRISED OF FIBERS DISTRIBUTED AT RANDOM WITH FIBERS THEREFROMEXTENDING INTO ENGAGEMENT WITH THE BASE ELEMENT AND A FLEXIBLE ADHESIVEEXTENDING THROUGHOUT SAID LAYER AND BONDING THE FIBERS OF THE LAYERAGAINST MOVEMENT RELATIVE TO EACH OTHER IN A COMPACTED CONDITION WHEREBYSAID LAYER IS RENDERED DIMENSIONALLY STABLE, SAID ADHESIVE ALSO BONDINGTHE LAYER TO THE BASE ELEMENT OF THE CARPETING AND BONDING THE PILEELEMENTS TO THE BASE ELEMENT OF THE CARPETING.
 4. A METHOD OF FORMINGPILE CARPETING HAVING IMPROVED DIMENSIONAL STABILITY WHICH COMPRISES THESTEPS OF FORMING A LAYER OF FIBROUS MATERIAL ON A REAR FACE OF A PIECEOF PILE CARPETING HAVING A BASE AND PILE ELEMENTS EXTEND-DING FROM AFRONT FACE OF THE BASE, APPLYING AN ADHESIVE IN A FLOWABLE STATE TO THELAYER OF FIBROUS MATERIAL, COMPRESSING THE LAYER OF FIBROUS MATERIALWHILE THE ADHESIVE IS IN A FLOWABLE STATE INTO A COMPACTED CONDITION ANDSIMULTANEOUSLY FORCING THE ADHESIVE THROUGHOUT THE LAYER AND INTO THEBASE OF THE PILE CARPETING, AND THEN DRYING THE ADHESIVE WHEREBY THEFIBERS OF THE LAYER ARE BONDED TOGETHER IN A COMPACTED CONDITION AND THELAYER IS BONDED TO THE BASE OF THE PILE CARPETING.